System Installation Guidevortek

Vortek Automated Theater Rigging System

Manufacturer Address:Daktronics Hoist, Inc.66 School StreetVictor, NY. 4564USA Phone: (585)94-5000Fax: (585)94-0545www.vortekrigging.com

Authorized European Representative:Vortek Europe BVSpaarpot 0, GeldropPost Office Box 9545600 AZ EindhovenThe Netherlands

Manufactured to U.S. Patents: 6,634,622 B1 and 6,691,986 B2

PrefaceSafety Information

. Mechanical installation

A. Layout of components B. Using Installation Blocks & Hoist Clips C. Uncrating of Vortek Hoists D. Installation of C-Channel Stiffeners E. Mounting of Vortek Hoists F. Loft Block installation G. Running Lift Lines and Terminations H. Installing the Battens

Installation of Vortek HoistsTable of Contents

4Preface

This guide will assist the installer with most common Vortek installations and scenarios showing basic layouts and wiring diagrams.

Each installation will have its own layout and drawings as specified by the Architect and Theater Consultant that will work best for the theater involved. Refer back to the drawings for specific information that may be needed.

If any questions arise that are not covered by this guide and the plan drawings please do not hesitate in contacting Daktronics Hoist, Inc. at our main office where we will assist you in solving the concerns at hand.

Our office phone number is:585-94-50008am to 5pm, Monday through Friday EST/EDT

When calling please specify whether you have an electrical or mechanical/rigging question and you will be directed to the person best suited to help you.

5Safety Information

Warning:Hazardous voltages within may cause severe electrical shock and/or burns. Only authorized personnel should carry out any installation, commissioning or maintenance of the electrical systems.

Attention: This symbol will indicate cautions or concerns that may need further consideration before implementing.

Specific information will be available with each appearance of this symbol.

Compliance with RegulationsThe Vortek system complies with the relevant European directives required for the CE mark, including: 98/7/EC: Machinery Directive 7//EEC: Low Voltage Directive 89/6/EEC: Electromagnetic Compatibility

Independent reviews/tests in support of above compliance

EN550 / Class A Radiated and Conducted Emissions EN6000-4- / Electrostatic Discharge EN6000-4-6 / Conducted Susceptibility EN60950, 6004 / Safety Review

Warnings, Cautions, and Notes

All Warning notes contained in this manual indicate information that may endanger personnel.

6Mechanical Installation

A. Layout of Components

When the truck(s) arrives with the Vortek Hoists, unloading and getting them situated for either storage or immediate installation will help make everything go smoother.

Each Vortek Hoist crate has a packing sheet attached that will specify what type of unit it is and the quantities supplied.

Each Vortek crate weighs in at 870 lbs.There are only two places where the Vortek Hoists can be lifted with a forklift.

One is from the end with a forklift that has fork tines that are a minimum 4 long, a maximum of 8-/ wide and thick if this location is used.

The other lifting point is from the side where the forks want to be spread as far as allowable within the space provided.

The Vortek Hoists are not balanced at center so care must be taken when moving the units.

There could be any number of different style units on your install ranging from units that pick up heavy loads and travel at a fixed rate of speed to lighter loads that travel at variable speeds.

Segregating the units as needed might save headaches later.

Figure 1

Figure 2

As shown in Figure

As shown in Figure

As shown in Figure

7This example shows one possible way the Vortek Hoists might be installed.It is here that you want to make sure that you have the right unit for each position. The most common Vortek Hoist models are the V66A, capable of lifting 00 lbs at 0-80ft/min and V76A units that lift 000 lbs at 0-0ft/min. Once out of the crate the units are virtually indistinguishable from each other except for the nameplate on top of the Electronics cabinet.

Each hoist is addressed at the factory and the specific address is marked on the side as a Node #. Node 57 would be the number 8 unit. If the node numbers get installed in the wrong place, as long as the units are correct for the type that it is supposed to be in that position this is not a big concern as we can re-address them in the field during commissioning.

If, however, the wrong type of unit is installed in a position that is specified for another then it will have to be un-installed and moved to the correct position.

8B. Using the Installation Blocks and Hoist Clips

Vortek has Installation Blocks and Hoisting Clips that will assist in lifting and mounting the Vortek Hoists to their placement position. While not every install will require or use the installation blocks, the hoist clips will likely to be used in nearly every situation.

Installation block w/ pivoting sheave

Installation Block w/ fixed sheave

Note that the Installation blocks go on the offstage side and the onstage side of the steel beams. This allows the space for the C-Channel stiffeners to be placed into the Backbone channel.

The installation blocks require a minimum of 9 spacing on the steel beams as they lift the Vortek Hoist into place as can be seen by the diagram below.

9The hoist clips install into the backbone to connect the Vortek Hoist to the lifting cables.

Here is the clip sitting in the backbone channel prior being spun 90 to lock into the channel.

And with it spun and ready to have the bolts tightened down.

Make sure that these bolts are set or the clip could slip out of the backbone channel.

Directly attach your lift lines to the Hoist Clip with a /6 thimble and nicopress swage. While wire rope clips can work they take away lifting height of the clips.

Be certain that you have enough length on your wire rope for the total distance of the lift.

Given the variables with each installation we are unable to give specific cable lengths here.

Figure 3

As shown in Figure

0

C: Uncrating the Vortek Hoists

When you are ready to open the Vortek Hoist crates, move it under the position where it is to be installed.

The wooden shipping container is a two-piece unit. The top portion that consists of the top, ends, and sides are one unit. There is a bottom skid that the Vortek Hoist rides on.

Screws are driven into the bottom skid at each vertical slat just above the bottommost horizontal slat. There are 0 Phillip-head screws holding the top portion to the skid.

Vortek would like the shipping crates to be returned for re-use so please be diligent when removing and re-installing the screws.

When all 0 screws have been removed, two people can remove the top portion of the shipping crate.

Cut the banding and remove the poly sheeting from the Vortek Hoist. On top of the Vortek Hoist unit you will find two C-channel stiffeners that will be loosely attached at this time.

Figure 4

As shown in Figure 4

D. Attaching the C-Channel Stiffeners

After you remove the banding and poly sheeting there are two aluminum C-Channels on top of the Vortek Hoist with two /8 threaded rods and 4 nuts.

Turn the C-Channel on edge with the chamfered corner down and towards the beam clamps.

Run the threaded rod through the beam clamp while threading the nut onto it. Continue pushing the rod into the hole on the C-Channel and start threading the second nut onto it. The threaded rod will run into and through the second beam clamp.

Tighten up both nuts onto the C-Channel being aware to even the ends of the threaded rod that may be sticking out of the beam clips.

Note that the beam clamps nearest the electrical enclosure are pinned to the backbone and will not slide in the channels. They sometimes are at the very end of the backbone; and if this is your situation then the C-Channels will need to be installed after the unit is semi-installed onto the I-Beam.

The two remaining pieces that came with the C-Channels are the C-Channel Clamps. They hold the tops of the C-Channels together.

Set a clamp onto a single C-Channel and slide it about 6 past the end of the second channel. Repeat for the other end of the channels with the second clamp.

Do not tighten the set screw on these clamps at this time.

Not all Vortek Hoist installations will require the use of these C-Channel stiffeners. There may be three sets of beam clamps instead, like the image that is below.

E. Mounting the Vortek Hoist

Youre ready to lift the Vortek Hoist into position when installation blocks are on the I-beams and tightened down. The hoist clips are in place and tight.

The Vortek Hoist weighs approximately 650 lbs out of the crate. Precautions must be taken when lifting, making sure that the area is roped off and un-necessary personnel are cleared from the area.

Lift the hoist up out of the skid just a few inches to assure that everything is working the way it was planned. Make sure nothing askew is happening and that all connections are secure at the installation blocks and hoist clips.

When the Vortek Hoist reaches the I-beams, stop just short so that the beam clamps can be adjusted for the spread of the I-beams. Remember that the beam clamps nearest the electrical cabinet are fixed, and will not slide.

Raise and maneuver the hoist so that the pinned clamps will be the first to be tightened. Tighten the 9/6 bolts to just where the flat edge of the beam clamp is resting on the I-Beam. (see diagram below)

It is helpful to use a Cordless Impact driver like the DeWalt or Makita units with a wobble extension drive with a short socket.

Center the onstage beam clamps under its support beam and similarly tighten the bolts so that the flat portion of the beam clamp is supporting the hoist. Leaving the hoist clips in place, slacken the hoisting cables a small amount, confirming attachment to the I-beam

4

At this point, confirm the placement of the hoist, making any final fine adjustments by sliding the hoist upstage or downstage on the I-beam as needed.

For some installations this may be the technique needed to fit hoists into areas without enough room to use the installation blocks.

If the C-Channel Stiffeners were not installed earlier please do so now.

With placement confirmed, tighten the pinned beam clamps first by alternating between the two clamps until the hoist backbone is contacting the I-beam. Repeat for the onstage set of beam clamps.

Tighten the beam clamp bolts to 17-20 ft/lbs maximum!

As the beam clamps are tightened, the C-Channel stiffeners will be drawn onto the I-beam for additional support. The threaded rod will bend and apply constant pressure to the C-Channels to minimize vibration and noise.

5

When all beam clamps are tightened and torqued to the proper specifications, the -0 hex bolts on the sliding beam clamps must now be screwed down tight securing the clamps to the backbone.

With the Vortek Hoist in place on the I-beam the C-Channel Stiffener clamps can have their set screws tightened down to ensure that the C-Channels will not spread apart.

The installed Vortek Hoist will look like this when final installation is complete.

Figure 5

As shown in Figure 5

6

F. Installation of Loft Blocks

There are two types of Vortek Loft blocks, the multi-line and single line. Both will mount to the I-beams in a similar fashion as the Vortek Hoist.

When the Vortek Hoists were first laid out there should have been a zero reference point to start all of your measurements from.

Determine the center of each hoist (4.5 from edge of the hoist) and snap a chalk line to the other side of the stage on each beam position confirming that it the same location as the Vortek Hoist center.

All of your Multi-line Loft Blocks will mount on the beams closest to the Vortek Hoist with the Single Line Block being on the beam furthest away.

Identifying the two blocks is easy; the single line block is about the width of the multi line block.

7

Mount these blocks by centering the block into position and tightening the nut on the bolt. Repeat this for all blocks. Tighten the nut on the loft blocks to 17 20 ft/lbs torque.

Due to wider I-beams at some installations, the loft blocks may contain a spacer located against the inside surface of the loft block hooks. These I-beams will rest against the spacers. Some adjustment may be necessary of these spacers.

This diagram shows alternating Vortek Hoists in one possible layout.

Vortek Hoist configurations maximize lifting capacities by using double purchased loft blocks A after the model number, such as V66A or V76A, designates these Vortek Hoists.

Below is a double purchase multi-line loft block with the additional single line sheave at the batten connection and a dead off attachment point at the I-beam.

8

Running and terminating Lift lines

The Vortek Hoists have up to 7 lift lines per batten and depending on the installation. All lift lines my come out of the end of the hoist, or there may be one or two cables coming directly out of the unit.

All of the cable is coiled and tied with a colored Ty-Rap indicating which drop the cable is specified for.

From shortest to longest the color code is:

The order as the lift lines coming of out the end of the Vortek Hoist start at center as the shortest lift line and the longest towards the outside of the hoist.

This unit has 5 lines: that drop directly out of the hoist and out of the tail end.

In this instance you would have lift lines , 4, and 5 coming out of the end as seen from left to right.

When running the lift lines into the loft blocks, start with the shortest line and work to the longest.

Red - Motor End drop directly out of the Vortek Hoist or 1st drop closest to hoist.

White - Tail end drop directly out of the Vortek Hoist or 2nd drop.

Black - 3rd drop from hoist

Green - 4th drop from hoist

Purple - 5th drop from hoist

Yellow - 6th drop from hoist

Orange - 7th drop from hoist

9

Be careful not to have the through cables cross over each other when running them.

The pass through area on the block is not load bearing. Make sure that the lift line drops onto the load sheave for each drop.

The last loft block will be of a single line sheave style.

Terminating the wire rope cables

The cables have been fed through the loft blocks assuring that there are no crossed lines and the excess is on the ground.

In most situations the theater consultant or architect will specify a trim height for the battens to reside at when at their lowest point. With the Vortek Hoists this is not a necessity since the low trim can be adjusted via limit switches or by the Vortek Automation Center.

Therefore, instead of cutting the cables at a high enough point to attach turnbuckles or chain and batten to be at the specified trim height, cut the cables just high enough to allow the batten to float off the ground when the turnbuckle or chain is attached. The suggestion is to cut the cables about - off the ground and do all of your batten terminations at this height.

The first drop will feed onto the load bearing sheave.

The remaining drops will pass through the block.Figure 6

Figure 7

As shown in Figure 6

As shown in Figure 7

0

If you have double purchase units do not cut the cable! These must be terminated at the I-beams on the dead-off connection.

/6 wire rope used in the Vortek Hoists for all configurations and in almost every installation a /6 Nicopress copper sleeve with thimble is used to finish the cable end.

Vortek recommends that only copper sleeves or zinc coated copper sleeves be used for terminations. Aluminum sleeves are NOT acceptable for cable terminations.

Be aware of minimum height needs for each batten. Double piped electrics will need to have their cable terminations done higher than normal single pipe battens.

Installation tips

Most installers will have their own way of finishing off the cable terminations; however here is some helpful advice.

Take one cable drop before cutting and slip a Nicopress sleeve onto it. Create the loop with the /6 thimble and attach your turnbuckle or chain and do a quick check of batten height to assure that all components will float off the ground at an appropriate height. Pull the cable taut if coming off a loft block. There may be some slack between the hoist and the loft block.

Mark the wire rope cable just above the Nicopress sleeve on the tail end side of the cable with a permanent marker and remove all components.

Cut the wire rope at the indicated spot. Take a scrap piece of EMT conduit or a wood dowel that is tall enough to stand on end and stand it next to the cable end. With a piece of electrical tape or other marking tape, mark the conduit/dowel where the cable ends. You can use the tape top edge or bottom edge or even mark the tape if you want. Just remember where your indicator is.

With your measuring device in hand now you can just go along to each cable drop, stand it up next to the cable and cut it with a lot less fuss. Remember to pull the cable taut before marking/cutting.

66 School Street Victor, New York 4564 USA

tel 585-94-5000 fax 585-94-0545

www.vortekrigging.com email sales@vortekrigging.com

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